Flat-Folding Box Covers and Method of Assembly

ABSTRACT

A flat-folding box cover with magnets on one edge of the side panels that align with magnets of the opposite polarity on flaps of the adjacent side panel to hold the box into position is provided. The flat-folding box includes a top panel with aperture and four side panels that when assembled fits over the top of a tissue or other box. The portions of the side panels that form the inside of the box are lined with material to protect the magnets. 
     The box covers may be sold finished from a seller. In another case, consumers may select from a set of options provided by a seller for the box cover design. In another case, the consumer may supply the seller with custom artifacts such as photos or artwork which the seller would incorporate into the finished box cover. Kits may also be sold allowing the purchaser to customize the box cover themselves.

This patent claims the benefit of Provisional Patent 62088657, filed on 2014 Dec. 7 with an extension filed on 2015 Dec. 7. Provisional Patent filed by Eduardo E. Drake, Registration #40594.

COPYRIGHT NOTICE AND PERMISSION

A portion of this patent document contains material subject to copyright protection from the inventors' original provisional patent, 62088657, which had a copyright claimed in 2014 with the copyright holders consisting of Jeanne H. Etem, Julie M. Etem and Sherrie L. Sullivan.

BACKGROUND - PRIOR ART U.S. Patents Kind Patent number Code Issue Date Patentee U.S. Pat. No. 5,140,562 A 1992 Aug. 13 James Crispi U.S. Pat. No. 5,497,876 A 1996 Mar. 12 Barbara Fleming U.S. Pat. No. 5,639,523 A 1997 Jun. 17 Diana Ellis U.S. Pat. No. 6,884,081 B1 2005 Apr. 26 Joseph Ovadia U.S. Pat. No. 7,665,628 B1 2010 Feb. 23 Loren Milligan U.S. Pat. No. 7,737,391 B2 2010 Jun. 15 Leslie Thomas Long US D390391 S1 1998 Feb. 10 Junior Julian Hau US D494859 S1 2004 Aug. 24 Gerald J. Keberlein US D514928 S1 2006 Feb. 14 Gerald J. Keberlein

U.S. Patent Applications Kind Publication number Code Publication Date Applicant 20020067038 A1 2002 Jun. 6 Lam Tran 20030205613 A1 2003 Nov. 6 Angela Schliebner 20060049067 A1 2006 Mar. 9 Duane McDonald 20090212096 A1 2009 Aug. 27 Helmut Sieber 20130097834 A1 2013 Apr. 25 John Anthony Pacione

1. FIELD OF THE INVENTION

The present invention relates generally to flat-folding box covers, with specific emphasis on tissue box covers.

2. BACKGROUND OF THE INVENTION FIELD

Decorative boxes, specifically tissue boxes, typically are created by adding designs on the cardstock tissue box at the tissue box, or cardstock manufacturer. A second approach to offering decorative tissue boxes are rigid tissue box covers as evidenced in design patents, D390391, D494859, and D514928. The tissue boxes with a decorative design have graphics but they don't have the sheen of laminated paper, nor the flexibility to customize the box look. Another issue is that the tissue boxes need to be glued, limiting their use to one-time. If the tissue boxes could be folded and reconfigured without adhesive, but rather had flaps and slots for assembly, they could be reused a limited number of times before the box configuration lost its crispness and consequently its decorative appeal. In an effort to give a more decorative permanent look numerous rigid box covers with more upscale designer looks have come onto the market. They are placed over the tissue box with versions available for both the square and rectangular tissue boxes. These rigid boxes for the most part cannot be customized, and their bulk also makes them expensive to ship. The present inventors saw three specific issues they wanted to address, one the need for a decorative, reusable box cover that could ship flat, two the need for a decorative reusable box cover that would not have its appearance degrade when it was taken apart and then reassembled and would therefore have a long life, and three a product design that would allow users to customize their box with their own designs.

DESCRIPTION OF PRIOR ART

Prior art descriptions are listed below.

1. Tissue boxes that have a waste receptacle built into the box. U.S. Pat. No. 5,145,062. This patent is based on a standard tissue box and doesn't have a decorative element, nor does it disclose a box that doesn't require adhesive or a box that can be folded together and then unfolded for later reuse.

2. 20130097834 claims a tissue box that is designed for production, with the emphasis on how they can be filled with tissues from the top or bottom.

3. Patents that detail a layout on a one piece blank for a box to simplify graphic production, US20060049067A1 or a graphic design on a one piece blank that can be folded into a box, U.S. Pat. No. 5,497,876. U.S. Pat. No. 5,497,876 is probably the closest invention to the invention claimed in this application. The difference is that the box is folded together with one piece of the cutout going into a slot or other holding mechanism in another part resulting in the lessening of the crisp box look and the loss of rigidity each time the box is constructed. The product is designed for one-time use as a gift box.

4. Tissue box covers that retain a three dimensional shape and do not go flat; they are rigid boxes. U.S. Pat. No. 7,665,628 and US D390391.

5. US D514928 claims a tissue box cover from a one piece paper cutout that folds together. This patent claims a different one piece paper layout than the product claimed in this application, and is not designed for multiple reuses.

6. US D494859 claims a triangular tissue box, and not a tissue box cover.

7. 20020067038 claims a tissue box cover that has inserts for photos or other decorative elements. The box has a rigid three dimensional shape and does not go flat when not in use.

8. 20030205613 claims a tissue box with a laminated piece that covers the tissue box orifice so that tissue does not get damaged. The application also discloses a flat sheet layout for production that folds into a tissue box. This flat layout is not the same as the product claimed in the current application.

9. 20090212096 claims a foldable box, made out of a flat sheet cutout, folding without the use of adhesives. The 20090212096 application relies on a decorative tab that is inserted into a cutout in the cardstock that holds the box together. The product claimed in this application does not have parts that fold into each other but instead uses magnets or other fasteners to hold the box cover together.

Other pertinent patents.

-   -   10. U.S. Pat. No. 5,639,523 relates to the use of transparent         plastic material with adhesive for decorative envelopes and         potentially for decorative boxes. The difference in this claim         and the invention disclosed in this application is that the         transparent plastic material in U.S. Pat. No. 5,639,523 is only         for decorative purposes, the invention claimed in this         application uses the laminating process to create a strong         durable box cover that can be used, then folded flat and then         used again multiple times. The main claim of this patent is for         a flat-folding box cover. Laminate, or a box cover without         coverings are all options of the flat-folding box cover's final         construction.     -   11. U.S. Pat. No. 6,884,081 relates to the use of magnets on a         jewelry box to hold the cover down, and not the use of magnets         to hold the box together as the product claimed here does. This         was the only patent discovered that used magnets in a decorative         box.

The prior art does not address the combination of all of the following points that led to the development of the product claimed in the current application.

-   -   a. The need for a box cover that can go completely flat for ease         of storage and economy of shipment.     -   b. A box cover that could be used multiple times and would         resist losing its “new box” look with multiple uses that a         foldable box (with tabs and cutout slots) undergoes.     -   c. A box cover that could be modified to display images         furnished by the eventual retail purchaser to create their own         custom box cover.

SUMMARY OF THE INVENTION Folding Box Covers

The flat-folding box cover of this invention has several features, with no one single feature alone responsible for the invention's desirable attributes. Without limiting the scope of the invention that will be described in the claims, prominent features will be discussed. The preferred embodiment of the flat-folding box cover consists of a top panel with an aperture and four hinged side panels, all made of decorative or plain cardstock covered with plastic transparent laminate on the outside, and all four side panels and the top supported with stiffening pieces. One side of each side panel has magnets embedded into the stiffening pieces, with magnets of one polarity placed so that no sets of magnets of one polarity will be adjacent upon assembly. Each side panel has two sets of flaps, one set of flaps that fold over the magnets of one polarity embedded in the stiffening pieces. The other flap has magnets of the opposite polarity positioned so that on assembly the magnets align with the magnets of one polarity embedded into the stiffening pieces.

Tab liners, are positioned over the magnets of opposite polarity on the side flaps. An end flap folds over the bottom of the side panels for a better decorative effect. The entire cardstock with magnets may be covered in some embodiments by an inner lining that covers the magnets as well as the interior surface. When assembled the flaps with magnets of the opposite polarity reside against the edge of the adjacent side panel with magnets of one polarity to form a magnetic bond that holds the box in place. The cardstock cutout piece is produced in one piece and is able to lie flat and can be formed into a box shape. The interfaces between the box top and four sides are scored or creased to facilitate folding. In the preferred embodiment of the folding box cover, the aperture will have a decorative ring around its edge. The box cover can be configured to cover all standard tissue box sizes and configured to go into other box shapes. Box covers can be configured to fit over dispensers for paper hand towels, moist hand wipes, cosmetic wipes, baby wipes etc.

In additional embodiments, the flat-folding box cover with a top panel and four side panels may be made of paper, cardboard, foam board, plastic and other materials.

In additional embodiments, the decorative designs might be furnished by the end user either to the manufacturer or the selling entity for use as decoration for either or both top panels and side panels.

In additional embodiments, the end user may select to customize some aspects of the configuration by choosing from a set of design options provided by a seller.

In additional embodiments the laminate might have slots where photos or other items could be inserted by the eventual purchaser.

In some embodiments, the flat-folding box cover might be embellished with various materials such as beads, trim, borders, stickers and other decorative materials.

In some embodiments, the plastic transparent laminate material is not used.

In some cases a coating might be applied to the decorative pattern to add decorative appeal, or water resistance or strength to the cardstock, or all three.

In some embodiments the flat-folding box cover fasteners may be snaps, hook and loop, or other fastening devices. The number, size and placement of the fasteners may vary.

In some embodiments the aperture on the top of the flat-folding box cover will not have a decorative ring.

In some embodiments the cardstock cutout may have different layouts to create the flat-folding box.

In some additional embodiments the flat-folding box cover will be produced in a kit format. Some of the potential kit embodiments are:

-   -   a. The kit may be an undecorated flat-folding box cover. The         consumer would supply the embellishments.     -   b. The kit may be a partial set of components. The consumer may         need to purchase additional items in order to complete a         flat-folding box cover.     -   c. The kit may be all inclusive with everything needed to make a         flat-folding box cover and may include, but is not limited to:         decorative layers, lining layers, coating/protective layers,         panels, stiffeners, fasteners, decorative ring, adhesives, and         embellishments. The kit may contain the actual components or the         patterns from which components may be created.     -   d. The kit may include software to create embellishments.     -   e. The kit may specify links to websites where embellishments         may be created, purchased or downloaded.

The method or steps for constructing a finished box cover from the flat-folding cardstock cutout are comprised of:

-   -   a. The flat-folding box cover is positioned with the decorative         surface down     -   b. magnets of one polarity are placed onto side panels;     -   c. magnets of the opposite polarity are placed on the side flaps         on the other side of the side panels from the magnets of one         polarity;     -   d. the flaps holding magnets on the side panels are turned 90         degrees away from the decorative side of the flat-folding box         cover;     -   e. the side panels of the cardstock cutout are folded away from         the top panel into a box shape.     -   f. the magnets of opposite polarity on the side flaps are         aligned with the magnets of one polarity on the edge of the side         panels to create a finished box cover.

Advantages of the Invention

The five most prominent advantages of the invention are:

-   -   1. the use of decorative laminated material mimics the         decorative look of more expensive rigid box covers;     -   2. the use of magnets or other fasteners allows the flat-folding         box to be re-used multiple times without any loss of visual         appeal;     -   3. the flat-folding box folds flat, which offers less expensive         shipping and more convenient storage options;     -   4. the invention lends itself to customization         -   a. In one case, the consumer selects a configuration from a             set of options provided by the seller such as the size of             the box cover, the decoration on the top and side panels and             the style of the decorative ring.         -   b. In the other case, the consumer would supply the design             artifacts (photos, artwork etc.) to the seller who would use             them as the decoration for the box cover. The consumer could             also select from a set of options such as the size of the             box cover and the style of the decorative ring.     -   5. the invention lends itself to hobby & craft kits

DRAWINGS—FIGURES

FIG. 1 is a view of the decorative side of the cardstock cutout with magnets of one polarity on the side panels and magnets of opposite polarity on flaps;

FIG. 2 is a view of the decorative side of the cardstock adding stiffening panel, magnets of one polarity in the stiffening panels and tab liners over the flaps with magnets of opposite polarity;

FIG. 3 is a view of the non-decorative side of the cardstock cutout with flaps folded over;

FIG. 4 is a view of the cardstock cutout converted to a box;

FIG. 5 is a side view of how the magnets align when converted to a box;

FIG. 6 is a top view of the box with its decorative ring.

FIG. 7 is a view of a different embodiment cardstock cutout

FIG. 8 is a view of combining two pieces of the embodiment of FIG. 7 for production efficiencies;

FIG. 9 is a view of another embodiment of the cardstock cutout.

REFERENCE NUMBERS

-   1. Side panel with decoration -   1A. Stiffening pieces for side panels -   2. Top panel -   2A. Stiffening piece for top panel -   3. Aperture -   3A. Metallic Aperture Ring -   4. Magnets of one polarity on one edge of side panels -   4A. Magnets of opposite polarity -   5. Side flaps with magnets of the opposite polarity -   5A. Tab liners -   6. Side flaps without magnets -   7. Cutline between flaps -   8. End flaps

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 views the basic cardstock cutout from the decorative side with magnets of one polarity on the side panels and magnets of the opposite polarity on the appropriate flaps which is the basic starting point for many of the embodiments. Four side panels 1 with magnets of one polarity 4 and a top panel 2 with aperture 3, side flaps without magnets 6 and side flaps 5 with magnets of the opposite polarity 4A. FIG. 1 also has and end flaps 8 which fold over the end for a completed look. (Shown in FIG. 3) The cutline 7 separates the flaps of the side panels.

The preferred embodiment of the invention is shown in FIG. 2 from the view of the inside surface of the cover prior to being assembled into a box cover. The top panel 2 has a stiffening piece 2A, an aperture 3 and an aperture ring 3A. The four side panels 1 have stiffening pieces 1A, have magnets of one polarity 4 embedded on one edge of the stiffening pieces. Side flaps 5 with magnets of the opposite polarity 4A are arranged at a 90 degree angle to the side panels where magnets of one polarity 4 are on the inside edge of the stiffening pieces. Tab liners 5A are placed over the flaps with magnets of the opposite polarity.

FIG. 3 shows the flat-folding box cover right before it is assembled into the box. The end flap 8 has been folded over the end of each side stiffening piece 1A. Side flaps without magnets 6 have been folded over the magnets of one polarity 4 on the edge of the side stiffening pieces. The side flaps 5 with magnets of the opposite polarity 4A are turned at a right angle to the side panel, tab liners 5A are placed over the side flaps with magnets 5 of the opposite polarity 4A

FIG. 4 shows the flat-folded box cover as assembled. Magnets with one polarity 4 and magnets with the opposite polarity 4A overlap and are with shown with two sets of dashes, small dashes for magnets of one polarity 4, that are on the edge of the stiffening panels 1A and longer dashes for magnets of the opposite polarity 4A that are on the flaps with magnets 5. When the box is assembled the two sets of magnets align and hold the box together.

FIG. 5. shows how magnets of one polarity 4 on the edge of the side panels 1 align with the magnets of opposite polarity 4A on the side flaps with magnets 5 when the box is assembled.

FIG. 6. shows the top panel 2, stiffening piece for top panel 2A with the aperture 3 and aperture ring 3A.

FIG. 7. shows an alternative embodiment of the cardstock cutout for the flat-folding box cover which can also be assembled into a box cover.

FIG. 8. shows how two of the embodiments in FIG. 7 could be produced in order to cut waste.

FIG. 9. shows a third embodiment of the cardstock cutout for the flat-folding box cover. 

We claim:
 1. A flat-folding box cover for tissues and other items that provides decorative options comprising: a. a flat-sheet cardstock cutout with a top panel and four side panels of proper dimensions and of the proper location for a desired size folded box cover with an aperture in the middle of the top panel; b. the side panels on the cardstock cutout each having magnets of one polarity on one edge; c. the side panels having one set of side flaps on the opposite edge of the side panel with magnets of the opposite polarity.
 2. The device of claim 1 wherein the top panel and four side panels have decorative images.
 3. The device of claim 1 wherein the cutout is a five section flat-sheet cardstock cutout with the top panel aperture in the middle piece, and four side panels extending, one each, from the four edges of the top panel;
 4. The device of claim 1 wherein said cutout has scored line between the edges of top panel and side panels;
 5. The device of claim 1 with stiffening pieces attached to the side and top panels;
 6. The device of claim 1 wherein magnets are positioned on one edge of the side panels, and the flaps on the edge of the side panels are folded over the magnets and fastened to side panels;
 7. The device of claim 1 wherein the flap on the other side of each side panel from the edge with magnets have magnets positioned on them to align with the magnets on the edge of adjacent side panels;
 8. The device of claim 1 wherein an inner lining of material is fastened to interior surface of the cardstock cutout, covering the top panel, side panels and flaps with magnets;
 9. The device of claim 1 wherein an ornamental metal or plastic or other material, reinforcing ring, the same dimensions as the aperture in the top panel in the cardstock cutout, is placed around the aperture opening.
 10. The device of claim 1 wherein a transparent laminate sheet is placed over the decorative images.
 11. The device of claim 1 where a coating is placed over the decorative images.
 12. The device of claim 1 where lamination sheets are applied by the retail purchaser or retail seller after applying their images of their choosing as the decorative image.
 13. The device of claim 1 where the edges between the top and side panels are folded.
 14. A method of constructing a finished box cover from cardstock cutout comprised of: a. The flat-folding box cover is positioned with the decorative surface down b. magnets of one polarity are placed onto side panels; c. magnets of the opposite polarity are placed on the side flaps on the other side of the side panels from the magnets of one polarity; d. the flaps holding magnets on the side panels are turned 90 degrees away from the decorative side of the flat-folding box cover; e. the side panels of the cardstock cutout are folded away from the top panel into a box shape; f. the magnets of opposite polarity on the side flaps are aligned with the magnets of one polarity on the edge of the side panels to create a finished box cover.
 15. A method for customizing the flat-folding box cover by a seller with images furnished by an end-user comprising: a. The box of claim 1 is furnished to a flat-folding box cover seller in a state ready for customization b. The end-user furnishes the images for the top and/or side panels to the seller; c. The end-user may also select from additional design options provided by the seller; d. The seller completes the flat-folding box as specified by the end-user; e. The seller supplies the completed flat-folding box cover to the end-user.
 16. The method of claim 15 wherein all of the possible design options are furnished by the seller.
 17. A method for customizing the flat-folding box cover by the end-user comprising: a. The box of claim 1 is furnished to a flat-folding box cover end-user in a state ready for customization b. The end-user furnishes the design elements for the flat-folding box cover c. The end-user applies the design elements to the flat-folding box cover.
 18. The method of claim 17 where in all potential design options are furnished to the end user in the kit. 